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What are the essential components of TPM implementation for manufacturing success?

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Total Productive Maintenance (TPM) is a holistic approach to optimize the performance and reliability of manufacturing equipment. It involves the collaboration of all employees, from operators to managers, to prevent breakdowns, defects, and waste. TPM can help you achieve higher productivity, quality, and customer satisfaction. But how do you implement TPM successfully in your manufacturing facility? Here are the essential components you need to consider.

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Giuliana Pamplona

Especialista em Gest?o e Melhoria Contínua na Indústria | TPM | 5S | Kaizen | Estratégia | Gest?o da Rotina |…
Mandar Hingnekar

Manager | L&T Energy Hydrocarbon | Technology & Automation, Manufacturing , Planning | Digital Enabler
Fernando Orio

Ingeniero Especialista en Procesos Industriales

1 Vision and Strategy

The first step is to define your vision and strategy for TPM implementation. What are your goals and objectives? How do you measure your current and desired performance? What are the benefits and challenges of TPM for your organization? You need to align your vision and strategy with your business needs and customer expectations, and communicate them clearly to all stakeholders. You also need to establish a TPM steering committee to oversee and coordinate the implementation process.

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Fernando Orio

Ingeniero Especialista en Procesos Industriales
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Algunos de los aspectos claves a tener en cuenta en toda aplicación TPM son: 1- Compromiso de la dirección 2- Aplicación progresiva 3- Estructura de acompa?amiento 4- Pilotaje y control en todos los niveles 5- Comunicación permanente 6- Formación de todos los actores

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Giuliana Pamplona

Especialista em Gest?o e Melhoria Contínua na Indústria | TPM | 5S | Kaizen | Estratégia | Gest?o da Rotina | Consultoria | Mentoria | Treinamento | Instrutora TPM#203 | Oriento você na jornada da Excelência
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Antes de iniciar a implanta??o do TPM (ou de qualquer método de gest?o), se responda: "Quais problemas tenho hoje e que ser?o resolvidos com esse método? Quais objetivos quero atingir ao aplicar esse método?" Isso é alinhamento estratégico. Precisa ficar muito claro para a organiza??o como o TPM contribuirá para atingir a estratégia do negócio. Com essa clareza, fica muito fácil entender que o método é o meio para atingir o resultado.

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Fredrik Sandberg

Product Engineering Manager
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Find a common system or tool to log the maintence activities and visualize. Show the organization where the most critical equipment are. When this is information is readily available use it to establish your TPM strategy.

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2 Education and Training

The second step is to educate and train your employees on the principles and practices of TPM. You need to create a culture of continuous learning and improvement, where everyone is aware of their roles and responsibilities in maintaining and enhancing the equipment. You need to provide regular training sessions, workshops, and coaching to equip your employees with the skills and knowledge they need to perform TPM activities. You also need to encourage feedback and suggestions from your employees to identify and solve problems.

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Mohamed Gamal

Warehouse manger birla carbon egypt MQM,Nebosh safety IGC1,2,3 ,Nebosh Env., IOSH, Nasp, OSHA, 6sigma , PMP, ISO 45001 , 14001& 9001 Lead auditor & CPIM
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education & training to skill every person on organization in his job to reach to high skill on the job to ensure that the knoweldge for the job 're each to high & advance level by knoweldge & skill n the work place through skill diagram which people will start to suggest to improve the work place operation & help others to innovate new suggestion to improve working area

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Giuliana Pamplona

Especialista em Gest?o e Melhoria Contínua na Indústria | TPM | 5S | Kaizen | Estratégia | Gest?o da Rotina | Consultoria | Mentoria | Treinamento | Instrutora TPM#203 | Oriento você na jornada da Excelência
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TPM nada mais é do que uma mudan?a na cultura de gest?o da empresa, portanto, para que tenha sucesso, é imprescindível o desenvolvimento e engajamento de todas as pessoas. E o primeiro passo para isso é levar conhecimento a todas as pessoas.

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3 Autonomous Maintenance

The third step is to implement autonomous maintenance, which is the practice of empowering operators to take care of their own equipment. You need to train your operators to perform basic tasks such as cleaning, inspecting, lubricating, and adjusting the equipment, as well as detecting and reporting any abnormalities. You need to provide them with the tools and resources they need to perform these tasks safely and effectively. You also need to standardize the procedures and checklists for autonomous maintenance, and audit them regularly.

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Giuliana Pamplona

Especialista em Gest?o e Melhoria Contínua na Indústria | TPM | 5S | Kaizen | Estratégia | Gest?o da Rotina | Consultoria | Mentoria | Treinamento | Instrutora TPM#203 | Oriento você na jornada da Excelência
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Manuten??o Aut?noma é um dos pilares do TPM que tem a pessoa de opera??o como protagonista. O principal objetivo de MA é capacitar a pessoa de opera??o para manter seu euqipamento e seu processo nas condi??es ótima de modo a n?o ter defeitos, quebras e acidentes. Um equívoco é achar que o operador tomará o lugar do técnico de manuten??o. Na verdade, o operador passará a ter conhecimento e autonomia para fazer 4 atividades básicas: limpeza, inspe??o, lubrifica??o e reaperto, desde que sejam atividades simples e que n?o necessitem de ferramentas complexas e desmontagem. As atividades de alta complexidade continuar?o nas m?os dos técnicos de manuten??o.

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Mandar Hingnekar

Manager | L&T Energy Hydrocarbon | Technology & Automation, Manufacturing , Planning | Digital Enabler
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In my opinion, autonomous maintenance is the most important step. In our organization, during the TPM round we used to put RED TAGS (major issues, to be attended by maintenance) & WHITE TAGS (minor issues, to be attended by operators). As the TPM journey progressed, we started trying to convert RED TAGS into WHITE TAGS, meaning training the operators to attend some of the major issues by themselves.. This is a big step in reducing the downtime of the machine as Operators are in the best position to identify & sometimes even predict the major issues. This also improved their knowledge of the machine operation resulting in cascading effect in terms of benefits..

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Fredrik Sandberg

Product Engineering Manager
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In my experience it is important to give continous and relevant feedback to the operator regarding the maintenance activities. This is most important for reported deviations. - What are the maintenance organization doing to mitigate your report deviation. Explain wat could be the impact if it was not reported.

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4 Planned Maintenance

The fourth step is to implement planned maintenance, which is the practice of scheduling and performing preventive and predictive maintenance on the equipment. You need to analyze the data and information from the autonomous maintenance, as well as from other sources such as sensors, manuals, and records, to determine the optimal maintenance intervals and methods for each equipment. You need to assign and train your maintenance technicians to perform these tasks efficiently and accurately. You also need to monitor and evaluate the results and impacts of planned maintenance, and adjust them as needed.

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Giuliana Pamplona

Especialista em Gest?o e Melhoria Contínua na Indústria | TPM | 5S | Kaizen | Estratégia | Gest?o da Rotina | Consultoria | Mentoria | Treinamento | Instrutora TPM#203 | Oriento você na jornada da Excelência
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O Pilar de Manuten??o Planejada tem como principal objetivo garantir a quebra zero. Para tanto, implantará um sistema robusto de manuten??o de modo que se trabalhe de forma preventiva e planejada, em vez de atuar apenas de forma corretiva (após os problemas aparecerem). Um ponto fundamental é entender que manuten??o planejada engloba toda e qualquer atividade que mantenha as condi??es ótimas dos equipamentos, ou seja, inclui as atividades realizadas pelos operadores (manuten??o aut?noma) e pelos técnicos de manuten??o (manuten??o profissional).

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5 Quality Maintenance

The fifth step is to implement quality maintenance, which is the practice of eliminating the root causes of defects and errors in the equipment. You need to use tools and techniques such as Pareto analysis, fishbone diagram, 5 whys, and 8D to identify and analyze the factors that affect the quality of your products and processes. You need to implement corrective and preventive actions to eliminate or reduce these factors, and verify their effectiveness. You also need to document and share the best practices and lessons learned from quality maintenance, and apply them to other equipment and areas.

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6 Focused Improvement

The sixth step is to implement focused improvement, which is the practice of using cross-functional teams to tackle specific problems or opportunities for improvement in the equipment. You need to select and prioritize the issues or goals that have the most impact on your performance and customer satisfaction, and assign them to the appropriate teams. You need to train and coach your teams on how to use tools and methods such as PDCA cycle, A3 report, and Kaizen to plan, execute, and evaluate their improvement projects. You also need to recognize and reward your teams for their achievements and contributions.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Giuliana Pamplona

Especialista em Gest?o e Melhoria Contínua na Indústria | TPM | 5S | Kaizen | Estratégia | Gest?o da Rotina | Consultoria | Mentoria | Treinamento | Instrutora TPM#203 | Oriento você na jornada da Excelência
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Em mais de 16 anos de implanta??o de TPM em grandes multinacionais, posso garantir que as chaves para o sucesso s?o: - Comprometimento da alta lideran?a na disponibiliza??o dos recursos e com a pra′tica do método - Capacita??o de todas as pessoas - Times multifuncionais (engajamento de pessoas de todas as áreas) - Senso de propósito: implantar o TPM e suas ferramentas porque há um objetivo claro a ser atingido (redu??o de custos, elimina??o de defeitos, redu??o de quebras, aumento de seguran?a) - Comunica??o clara com todas as pessoas da empresa

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What are the essential components of TPM implementation for manufacturing success?

1

2

3

4

5

6

7

1 Vision and Strategy

2 Education and Training

3 Autonomous Maintenance

4 Planned Maintenance

5 Quality Maintenance

6 Focused Improvement

7 Here’s what else to consider

Manufacturing

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What are the essential components of TPM implementation for manufacturing success?

1

2

3

4

5

6

7

1 Vision and Strategy

2 Education and Training

3 Autonomous Maintenance

4 Planned Maintenance

5 Quality Maintenance

6 Focused Improvement

7 Here’s what else to consider

Manufacturing

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感谢您的反馈

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